Proxima Ultralight SV1 User manual

Brand: Proxima

Model: Ultralight SV1

Category: Data projectors

Type: User manual

Technical Support Proxima ASA

Horsterweg 24, 6191 RX, Beek, The Netherlands

Tel: +31 43 358 5210 Fax: +31 43 358 5202

Ultralight SV1

MODULE LEVEL SERVICE MANUAL

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL2

1 TABLE OF CONTENTS

1 TABLE OF CONTENTS.........................................................................................................................2

2 REVISION HISTORY .............................................................................................................................2

3 SCOPE...................................................................................................................................................3

4 MODULE LEVEL SERVICE AGREEMENT ...........................................................................................3

5 ASSOCIATED DOCUMENTATION .......................................................................................................3

6 REPLACEMENT OF MODULE LEVEL ELEMENTS .............................................................................4

6.1 SAFETY GUIDELINES....................................................................................................................4

6.2 PROTECTIVE CLOTHING..............................................................................................................4

6.3 TOOLS............................................................................................................................................4

7 TROUBLESHOOTING...........................................................................................................................5

7.1 WORK PROCEDURES...................................................................................................................8

7.1.1 GENERAL PROCEDURES .....................................................................................................8

7.1.2 REPLACEMENT OF MECHANICAL AND ELECTRONIC PARTS .........................................9

8 WIRING CONNECTION DIAGRAM, TOP AND BOTTOM CABINET .................................................12

2 REVISION HISTORY

18.03.99 HM Draft of Module level service Manual for SVGA LCD PROJECTOR

08.06.99 HM Draft with referance to new SPP-structure

21.06.99 HM Release of revision A

17.08.99 HM Release of revision B

18.08.99 HM Release of revision C

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL3

3 SCOPE

This document describes the assembly of the SVGA LCD Projector unit at module level detail, and serves as

a guide for the replacement of such elements when the unit needs servicing. The document does not assist

in repairing the elements themselves (such as replacing individual components on the electronic circuit

boards).

The information contained in this document may be subject to change without prior notice.

4 MODULE LEVEL SERVICE AGREEMENT

Only the primary customer named in the Module level service Agreement may carry out the repairs detailed in

this document.

Any unauthorised repair that is performed outside the scope of this document will violate

any warranties and could potentially damage the unit.

5 ASSOCIATED DOCUMENTATION

For Sparepart & Accessory overview, please refer to the ASK web-page.

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL4

6 REPLACEMENT OF MODULE LEVEL ELEMENTS

The following procedures must only be carried out by qualified and experienced service

personnel authorized by means of the Module Level Service Agreement to perform module

level repairs on LCD projector units.

Always remember to test the product thoroughly immediately after service.

6.1 SAFETY GUIDELINES

The following safety guidelines should be followed at all times. Failure to do so could seriously damage the

projector unit, or create a hazard to the service personnel or projector unit owner, and may violate warranties

on the product.

This product operates on mains voltage. Make sure to unplug the power cord before

attempting to open the unit. To avoid burns, do not open the unit to replace parts until it has

cooled down completely after use. The interior of the projector becomes hot during operation.

Do not under any circumstances operate the lamp whilst the housing is open, as there is a risk

of permanent injury due to contact with high voltage elements, explosion of the glass lamp

bulb or exposure to high levels of UV radiation.

The UHP-lamp used is high voltage when starting and high-pressure when operating.

6.2 PROTECTIVE CLOTHING

The following protective clothing should be worn in addition to normal work clothing when servicing the unit:

• Static free cotton gloves

• Full face visor (for all replacements of illumination/optical module level elements)

6.3 TOOLS

The work should be performed at a static-free workstation. Work in a dust-free environment if possible and

have access to a high-pressure air blower to remove dust when assembling the unit.

The following tools are required to service the LCD projector unit:

ID TOOL USED FOR

1 Torx no. 10 screwdriver Replacing elements

2 Torx no. 8 screwdriver Replacing elements (e.g. main fan(s))

3 Pair of snipe-nosed pliers Miscellaneous (e.g. removing cables/springs)

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL5

7 TROUBLESHOOTING

This troubleshooting guide helps determining what parts to replace if a defective projector comes in for

service. Not all possible defects are described here, only the ones that are most likely to appear.

For replacement procedures, please refer to the Servicing the Unit-section following this section. For

pricing details of the various parts, please refer to the Sparepart and Accessories Pricelist-document

on the web. The numbers in brackets ( ) refer to the exploded drawing of the module level elements.

Please also refer to the User Guide for setting up the unit with different sources and other additional

information not available in this document.

PROBLEM PROBABLE CAUSE REMEDY

White image projected

only

Loss of image data

1. Bad flex cable connection

between main PCB controller

connector and Polysilicone engine

2. Main PCB

controller defective

3. Defective engine

1. Reconnect flex cable connectors (3 pcs)

(See “Work Procedures” in section 7.1.2

task “Main PCB Controller”)

2. Replace defective main PCB controller

and engine (considered one part)

3. Replace defective engine and PCB

controller (considered one part)

Lamp does not start up

(LEDs are lighted on top

panel, fans run)

Loss of lamp power

1. Defective lamp

2. Loss of enable signal to lamp

power supply

(6)

from main PCB

controller

3. Defective main PCB controller

4. Lamp power

(6)

(ballast unit)

defective

5. Defective mains filter

(4)

1. Replace defective lamp

2. Reconnect/secure loose enable

connector

(Green ~ 0.2V/5V, on/off

Red ~ 4V/0.1V, on/off

Black: GND)

3. Replace defective main PCB controller

and engine

4. Replace defective lamp power supply

5. Replace defective mains filter (~ + 400V

DC)

Complete unit

inoperative

(all operations inactive, no

light, no LED, no fan)

No power to internal functions

1. Bad connection between controller

power supply

(5)

to main PCB

controller

2. Broken mains fuse (F1 at mains

filter

(4)

)

Defective mains filter

(4)

1. Reconnect 6 pin PC-edge connector (DC

voltage to main PCB: GND 5V, 6V,

15.3V, 16.5V, 5V, 3.3V seen from front

GND towards projection lens)

2. Replace broken mains fuse

(Schurter Type: SP 2.5A Fast 250 VAC)

3. Replace defective mains filter (~ + 400V

DC)

Garbled video image

Loss of image synch or image data

1. User programmable parameters

illegal

1. Execute Factory Reset

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL6

PROBLEM PROBABLE CAUSE REMEDY

Excessive fan noise

Main fan(s) defective

1. Fan

(3)

defective

2. Fan mount out of position

1. Replace defective fan(s)/fanhouse

complete

2. Secure fan mount

Fan(s) is/are inoperative

Loss of power to fan(s)

1. Loose fan(s)

(3)

wiring connector

2. Defective fan(s)

(3)

3. Defective main PCB controller

1. Reconnect/secure wiring

2. Replace defective fan(s)/fanhouse

complete

3. Replace defective PCB controller

Dark spot in the middle

of the image, increasing

in size

Overheating of Polysilicone LCD

module

1. Dirty dustfilter

2. Loose Polysilicone engine fan

power connector

3. Defective Polysilicone engine fan

4. Defective lamp (too much heat

radiation)

5. Defective main PCB controller

1. Clean/replace dustfilter

2. Reconnect/secure loose Polysilicone

engine fan power connector

3. Return engine fan to producer for

replacement

4. Replace defective lamp

5. Replace defective PCB controller and

engine

Red, green or blue

colours are misaligned

in image

LCD modules misaligned in

Polysilicone engine

Centre of coinciding pixels may be up to 1,5

pixels’ width apart (gap of 0.5 pixels

between). This is still inside optical

specification

Line of pixels in different

color crossing the

image (hor/vert)

Defective line of pixels in LCD

module of the Polysilicone engine

Entire engine and main PCB controller

needs to be replaced

Parts of the projected

image are discoloured

or white

Defective field in LCD module of the

Polysilicone

Entire engine and main PCB controller

needs to be replaced

Image projected as

vertical or horizontal

lines only

Loss of image synch or image data

1. User programmable parameters

illegal

2. Bad connection between main

PCB controller controller

and

engine

3. Defective Polysilicone engine

4. Defective main PCB controller

1. Execute Factory Reset

2. Reconnect flex cable connector (See

“Work Procedures” in section 7.1.2)

3. Replace defective Polysilicone engine

and main PCB controller

4. Replace defective main PCB controller

and Polysilicone engine

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL7

PROBLEM PROBABLE CAUSE REMEDY

Fuse breaks instantly

Too much current to the unit

1. Wrong fuse value inserted on the

mains filter

(4)

(at F1)

2. DC power polarity to lamp power

supply inverted at the safety

switch

3. Defective lamp power supply

(6)

4. Defective mains filter

(4)

1. Replace fuse with correct value

(Schurter Type: SP 2.5A Fast 250 VAC)

2. Check DC power connection on safety

switch

3. Replace defective lamp power supply

4. Replace mains filter

Distorted noise from

speakers

Speaker(s)

defective (blown) Replace housing complete with speakers

Unit shuts off while

being used

Possible overheating

1. Defective main fan(s)

(3)

2. Dirty dustfilter

3. Defective lamp (too much heat

dissipation)

4. Defective 100°Celcius Bi-metal

thermo switch

5. Defective main PCB controller

6. Lamp power supply

(6)

(ballast

unit) defective

1. Replace defective main fan/fanhouse

complete or remove obstructing object

2. Clean/replace dustfilter

3. Replace defective lamp

4. Replace fanhouse with fans and thermo

switch

5. Replace defective main PCB controller

and engine

6. Replace defective lamp power supply

Image is flickering or

appears to be unstable

in light intensity

Lamp light is flickering

1. Defective lamp

2. Dirty dustfilter

3. Defective lamp power supply

(6)

4. Defective Polysilicone engine

1. Replace defective lamp

2. Clean/replace dirty dustfilter (overheating

of lamp)

3. Replace defective lamp power supply

4. Replace defective Polysilicone engine

and main PCB controller

Colours break up

1. Bad connection between engine

and main PCB controller

2. User settings not allowed

1. Secure/fix flex cable connection

(See “Work Procedures” in section 7.1.2)

2. Execute Factory reset

White vertical line

appears far right in

picture

Synchronization error Perform RESET on remote control or

projector panel

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL8

7.1 WORK PROCEDURES

The numbers in brackets ( ) refer to the exploded drawing of the module level elements. An estimate of the

time required for the replacement is also given as a guide for service charges.

7.1.1 GENERAL PROCEDURES

TASK PROCEDURE TIME REQ.

GENERAL

Opening the unit

• Unscrew the 8 pcs cabinet screws, 7 located on the sides of

the projector and 1 at the rear.

• Remove the zoom and focus rings as described in section

7.1.2.

• Carefully lift the housing top off the unit and disconnect the

speaker connectors at the front of the main PCB.

5 min.

Reassembling the unit

• This is assumed to be the necessary stages of any of the

procedures below performed in the reverse order, and finally

the reverse of the “Opening the unit” procedure above.

• No further instructions will be given unless they differ from

this.

5 min.

Always remember to make a note of the cable connections when performing service, as this

will be of great help when reassembling the product.

All references are seen from the front of the projector.

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL9

7.1.2 REPLACEMENT OF MECHANICAL AND ELECTRONIC PARTS

All replacement operations require that the unit is opened; an open unit is therefore assumed in the following

replacement procedures. The numbers in the left column and in the text refers to the exploded view

illustration.

REPLACEMENT OF MECHANICAL AND ELECTRONIC PARTS

# TASK PROCEDURE TIME REQ.

1 HOUSING

BOTTOM

(part of Housing

Complete)

• Remove the main PCB controller, Polysilicon engine, rear cover,

housing handle,

adjustable feet,

and dust cover with filter,

described in their respective sections.

• Replace the housing bottom

(1)

and remount in reverse order.

30 min.

2 PROJECTION

LENS

• Remove the main PCB controller and Polysilicon engine

described in their respective sections.

• Remove the zoom and focus rings as described below.

• Unscrew the 4 cross-slot screws holding the projection lens

(2)

to the

engine.

• Replace with new lens, making sure that the 2 plastic guides on the

lens enters their designated holes on the engine. Fasten the

screws.

• Remount the zoom/focus rings and reassemble the projector.

20 min.

Do not touch the optics; prism in engine or lens glass, as this

may severly reduce the optical quality or damage the engine

permanently.

ZOOM & FOCUS

RINGS

• Take hold of the focus ring

between your thumb and index finger.

• Apply pressure and pull/wriggle the ring off the projector lens. If this

is not sucessful, try moving your grip.

• Remove the housing top as described previously.

• To remove the zoom lens, turn the rear end of the projector towards

you.

• Place your thumbs behind the zoom ring on each side of the lens

and apply pressure outwards, until the ring slides off the lens.

• Replace with new rings and remount in reverse order.

2 min.

Make sure to enter the focus ring retainers onto the drilled pits

in the lens assembly rim groove. The zoom ring has 3 holes

which should be fitted onto the screw heads on the lens assy

and it is correctly fitted when you hear a clicking sound when

mounting.

3 FANHOUSE

COMPLETE

(w/ cooling fans

and thermo

switch)

• Remove the main PCB controller and the Polysilicon engine as

seen above.

• Remove the fanhouse

(3)

by unscrewing the 2 screws at the top and

1 screw at the bottom of the engine.

• Hold the engine in a firm grip with the lens pointing towards you,

your left hand supporting the rear left corner and your right hand

enclosing the rear right corner of the fanhouse.

• Bend the fanhouse carefully down sideways, releasing the 2 upper

plastic retainers and pull it away from the engine.

• Replace and remount in reverse order by snapping the fanhouse

onto the engine. Make sure that the retainers enters their

designated holes.

15 min.

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL10

REPLACEMENT OF MECHANICAL AND ELECTRONIC PARTS

# TASK PROCEDURE TIME

REQ.

MAIN PCB

CONTROLLER

Neither the Polysilicone engine nor the main PCB controller

are available as spare parts. If malfunction, please return the

complete engine including the main PCB controller for repair .

• Unscrew the 4 metal screws on top of the main PCB controller.

• Disconnect all plugs marked with silk print on the main PCB

controller.

• Disconnect the 3 flex cables from the PCB

to the engine. Loosen

the flex cables by carefully pulling the plastic retainers on the

connectors slightly out without removing and pull the flex cables out.

5 min

Be extremely careful when disconnecting the 3 pcs. flex

cables from the main PCB controller!

Do not disconnect the flex cables from the LCD modules!

If flex cables are damaged/torn you need to replace the entire

engine and main PCB controller.

• Disconnect the 6 pin PC-edge connector (controller power supply to

main PCB controller) on the left of the projector. To do so you need

to pull the adjacent corner of the main PCB controller and

simultaneously push the controller power supply downwards.

• Lift up the rear end of the main PCB controller and remove rear

cover

with fan by unscrewing the single nutwasher.

• Replace the main PCB controller and remount in reverse order.

POLYSILICONE

ENGINE

Neither the Polysilicone engine nor the main PCB controller

are not available as spare parts. If malfunction, please return

the complete engine including the main PCB controller for

repair.

• Remove the main PCB controller as seen above.

• Remove the lamp assembly

by loosening the 3 retainer screws on the

lamp lid at the housing bottom and pulling out the lamp assembly.

• Unscrew the 4 screws (Torx), 1 on each side of the aluminum

chassis sourrounding the projection lens, the single screw on the left

rear corner of the engine and the single screw at the left side of the

engine.

• Gently lift up the Polysilicone engine from the housing bottom in a

twisting movement to lenghten the ignitor cables and ease the

ignitor connector removement.

• Disconnect the ignitor cable connector from the engines fanhouse

(2)

by first bending one of the plastic retainers aside with a flat headed

screwdriver. Then bend the second retainer and push the connector

upwards from the engine.

• Remove the engine.

• Remove the lamp house before returning the engine. See separate

section.

• Replace with new engine and remount in reverse order.

10 min.

Make sure that the position of the connector is correct when

reassembled. The no 1 mark must point towards the

projection lens end.

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL11

REPLACEMENT OF MECHANICAL AND ELECTRONIC PARTS

# TASK PROCEDURE TIME

REQ.

4 MAINS FILTER

• Remove main PCB controller as described above.

• Remove the Polysilicon engine as described above.

• Release the snapon connector on the mains filter

(4)

• Replace and mount in reverse order, making sure that the

power supply enters the designated slots in the housing

bottom.

5 min.

5 CONTROLLER

POWER SUPPLY

• Remove main PCB controller as described above.

• Remove Polysilicon engine as described above.

• Pull out the controller power supply

(5)

and release the 2 snap

on DC connectors.

• Replace and mount in reverse order, making sure that the

power supply enters the designated slots in the housing

bottom.

15 min.

6 LAMP POWER

SUPPLY

• Remove main PCB controller as described above.

• Remove Polysilicon engine as described above.

• Disconnect the snap-on DC connector from the lamp power supply.

• Free the ignitor cables from the plastic guides in the housing

bottom. See separate section.

• Lift the lamp power supply

(6)

out of the housing bottom.

• Replace and mount in reverse order, making sure that the lamp

power supply enters the designated slots in the housing bottom.

15 min.

LAMP

ASSEMBLY

Use only original lamp and holder as specified in the user

guide/service web-page. The lamp is individually adjusted with

the holder to maintain optimum illumination. Replacement using

a different lamp may result in poor illumination, malfunction

(potentially explosion) and will void any warranties

2 min.

Do not touch the glass bulb or the coated surface of the

reflector. An explosion may occur as a consequence when the

unit is operated and the elements become hot.

Disconnect the power cord before opening the lamp lid to

change the lamp.

• Unscrew the 3 screws holding the lamp assembly and pull the

assembly out.

• Replace with new assembly in reverse order.

MODULE LEVEL Ultralight SV1 101.670

SERVICE MANUAL

Proxima ASA CONFIDENTIAL12

8 WIRING CONNECTION DIAGRAM, TOP AND BOTTOM CABINET

Proxima Ultralight SV1 User manual

Brand: Proxima

Model: Ultralight SV1

Category: Data projectors

Type: User manual

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Proxima Ultralight SV1 User manual

Proxima Ultralight SV1 User manual

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